'Garry' - EK sedan.

Hey Guys

Started posting this on another forum and thought I may as well keep you guys updated as well.

One day I will get a start to my van, until then I will be playing with this.

Garrison Grey, EK 1962 special sedan.

Not much of a car really, just another molested EK in need of a lot of work.

What it does have going for it, for me is a good solid base for building something that will have a few of my own touches.

Current motivation comes from a HK 186S, Trimatic.



Week one of picking the car up (February 2014)



A few weeks later, I pulled a spare grill down to polish, 50 hours of work later had something to put back into a car.



Original grill from car vs polished grill



Another week or so after the grill fit up. Removed the mud flaps, kicked on a set of EK hub caps which I had repainted the centres, lowered the front down a little with a set of Kings lowered springs and flipped a leaf in the rear.



Some time between the last shot and this one at the 2014 Berrima 'Grey Pride' run. Got a set of 5 BF goodrich Silvertown Wide whites fitted to a matched set of correct EK rims, had them blasted and 2 packed in Garrison Grey (can not stand white wheels with white walls, two different shades of white always makes one or the other look dirty). Also fitted up new grill bar badge, new lenses all around and some more general tidying up.



From there I had a small window to get a few other things done to the car before the 2014 Cowra FB EK nationals. Only have very few photos of the little jobs down to the car.

One of which was this one.
I had plans of just painting up the grill and radiator support bars. Though something which I had always thought looked funny with a bigger radiator is the shape of the radiator support bar vs the shape of the radiator corners. So after sectioning up a support bar into 7 pieces and welding it back together I ended up with this (before paint) Why? Because I can.



Old radiator support bar out of the car next to the one I sectioned up.



Trial fit up to the car



Also Had the car at the exhaust shop getting a new tail pipe bent up. Hated the old exhaust tip, location on were it exited and old tail pipe wasn't high enough over the diff (use to bottom out)... bloody Exhausting job!





Went to the Cowra FB EK Nationals and had a blast!

Did the 2014 NSW All Holden day, travelled down with Ted Brennan (Green roof chopped two door EK) and Steve Mowat (green EJ Wagon) Had a good weekend and scored a few good parts for the EK at the swapmeet.



Then I think I don't think I had turned a spanner on the car until this last week!
Got side tracked with a few of the cars (EJ sedan {next to the EK in the picture above} and a 64 Pontiac), also had other big problems with life (boring stuff).
Continued collecting parts for the car along the way for Garry, knowing one day I will get a chance to do somethings to the car.

Thursday however was the day to make some sort of a start.

Got one last photo of the car before it came apart. (worried that it may not go back together again for a long time)



I have known since the week that I had got it that it needed rust repairs to the parcel shelf (went to fit seat belts and realized some metal may need to be replaced to mount them to)

Rear seat came out, what was left of the parcel shelf cover and rear window out.
This is what I first find



After some time scrapping with a screw driver and paint scraper I decided to get the wire wheel on the grinder out... After and hour this is where I got to for the night.





Couple of holes!

Picked this up close to 12 months ago also for this job



So Friday was not a very productive day.

Woke up to this!



Left the rear window out of the grey car out side Thursday night



Anyhow, after having a family snow fight and a good thaw out in front of the heater. I made a start on prepping the replacement panel.



Cut over sized





I had then taken to it with my new toy



Result is a nice clean panel to work with.





Did not get much else done after this as visitors had turned up.



Got a little more done today.

Started off by fixing some holes in the window channel





Then moved onto the large Swiss cheese part. I cut the badly affected area out and placed the roughly cut to size/shape repair section in with a few tacks to do a final in place cut to make sure for a good fit.



Then after the trimming cut the section back out ready for some rust proofing before I fully weld in tomorrow... Hopefully



Cheers for now
Jon  

Here's a picture when Garry was visiting Innuendo.

Regards, Smooth

Got one side of the rear window area rust repairs finished up today.

Started off by using some butt weld clamps to get thing into position.





About half way through welding I needed to pull the panel down to the boot hinge bracket, a couple of self drilling screws used.



Welding all but finished.



Quick grind up. First time I've really tried to metal finish a repair panel with out seeing the welds once ground.



Then for a little cold gal paint until I'm ready to seal it up properly.



That is enough for one weekend, hope to get the other side finished after work during the week.
Cheers Jon  

excellent job very talented thanx wizard

A little more done today.

All metal work repairs done in the rear window channel areas.









Next up rear seat belt fit up.

Plan is to recess reels down 40mm.



Until Next time
Jon

Nice work Jon!

Well another week down, no where near as much done as I would like but got some good hours in never the less.

started off by folding up some seat belt recess boxes.





Once that was done, marked out where they had to go in the car and cut a good chunk of the metal I had just replaced in the car.

Note boot hinge support bar in the road.



Cut the bar out to drop the new box in.



Seat belt sitting in there to make sure I was on the right track.







Had a read of the relivent VSB

Note sizes required



Cut the reinforcing plates out of 3mm plate, they ended up being bigger than required (80mm x 60mm). Also installed some locating 5mm screws to stop it spinning.





Note the bevel on the edge and also the radiused corners as per the rules.



Reinforcing plate will be held up with some nyloc nuts (not tightened up to tight)



I then cut the other side into the car



Tacked the corners into place



Then cut the wings off (originally thought I may need them... plans changed along the way)



Ground the edge of the box flush with the parcel shelf one side at a time



Ran a 1mm cutting wheel up between the to edges to be welded



Welded one side and then moved onto the next



Ground smooth



Welded the boot hinge support bar to the box from under neath



These are the instructions from the seat belts that I'm fitting



The supplied washer that spaces the seat belt reel up (refereed to as ''trim spacer'') this will space the reel above the locating screws.



Now back out to the shed to finish the other side
Cheers Jon

This is a great post (and sure puts my work to shame)....

Rohan wrote:This is a great post (and sure puts my work to shame)....

Thanks Rohan

Very tidy work

Hey Guys,

Small update on some slow progress.

Started off Saturday morning with intentions of working on getting the gaps better around the boot lid.



Thought it was a good idea to strip the paint off to do so around the edges to give me the best idea on what areas need work.



Then got to the point where i said to myself I've gone this far why not keep going!



Plan is to have no badging on the boot lid.

Beaver panel is surprisingly good rust wise. Does have the almost factory bumper section join dents in the beaver though.



Worst of the rust on the drivers corner.



Saturday afternoon I went for a drive to Woodstock to pick up a panel cut for an idea that'has been kicking around in my head.

Plan is to recess the fuel filler like on the utes, vans and wagons. Small custom touch that should look factory when finished.



After a quick blast this morning.



Also knocked most of the dents out of the beaver this morning.

This week I should hopefully get to fixing the rust, make a start on getting the fuel filler recess into shape and position

Until next time
Jon  

A great Write Up and Great Work Jon.

An enjoyable read. Thank you for sharing.